Component Parts Inspection

COMPONENT PARTS INSPECTION





1. Inspect 5th gear synchronizer ring.
a. Check for wear or damage.
b. Check the braking effect of the synchronizer ring.
- Turn the synchronizer ring in one direction while pushing it to the gear cone. Check that the ring locks.
- If the braking effect is insufficient, apply a small amount of fine lapping compound between the synchronizer ring and gear cone. Lightly rub the synchronizer ring and gear cone together.

NOTICE: Ensure the fine lapping compound is completely washed off after rubbing.





c. Check again the braking effect of the synchronizer ring.
d. Using a feeler gauge, measure the clearance between the synchronizer ring back and gear spline end.
Minimum clearance: 0.6 mm (0.024 inch).
If the clearance is less than the minimum, replace the synchronizer ring and gear cone by applying a small amount of fine lapping compound.

NOTICE: Ensure the fine lapping compound is completely washed off after rubbing.





2. Inspect shift fork and hub sleeve clearance.
- Using a feeler gauge, measure the clearance between the hub sleeve and shift fork.
Maximum clearance: 1.0 mm (0.039 inch).
If the clearance exceeds the maximum, replace the shift fork or hub sleeve.
3. Remove transaxle case receiver.
- Remove the bolt and transaxle case receiver.





4. If necessary, replace input shaft front bearing.
a. Using SST, pull out the bearing.
SST 09612-65014





b. Using SST and a press, install a new bearing.
SST 09950-60010 (09951-00460), 09950-70010 (09951 -07150)





5. If necessary, replace output shaft front bearing.
a. Remove the bolt and bearing lock plate.
b. Using SST, pull out the bearing.
SST 09308-00010
c. Remove the output shaft front cover.





d. Install the output shaft front cover.

HINT: Install the output shaft front cover projection into the case side hollow.





e. Using SST and a press, install a new bearing.
SST 09950-60010 (09951-00620), 09950-70010 (09951 -07150)
f. Install the bearing lock plate and torque the bolt.
Torque: 11 N.m (8 ft. lbs.).
6. Install transaxle case receiver.
- Install the transaxle case receiver and torque the bolt.
Torque: 11 N.m (8 ft. lbs.).





7. If necessary, replace input shaft front oil seal.
a. Using a screwdriver, pry out the oil seal.
b. Using SST, drive in a new oil seal until its surface is flush with the transaxle case.
SST 09950-60010 (09951-00400), 09950-70010 (09951 -07150)
c. Coat the lip of the oil seal with Multi-Purpose (MP) grease.





8. If necessary, replace reverse restrict pin.
a. Using a hexagon wrench, remove the straight screw.
b. Using a pin punch and hammer, drive out the slotted spring pin.





c. Replace the reverse restrict pin.
d. Using a pin punch and hammer, drive in the slotted spring pin.
e. Apply sealant to the screw plug threads.
- Sealant: THREE BOND 1344, LOCTITE 242 or equivalent
f. Using a hexagon wrench, install the straight screw plug.
Torque: 13 N.m (9 ft. lbs.).